Utility Monitoring IoT Hardware System
Smart Electricity Monitoring Integrated with MES
The Utility Monitoring IoT Hardware from Opus One is an advanced industrial energy monitoring system that enables real-time electricity consumption tracking across machines, production lines, and manufacturing plants. Fully integrated with the Opus One Manufacturing Execution System (MES), the solution converts raw power data into actionable manufacturing insights. Monitor, analyze, and optimize energy consumption in real time, reducing operational costs and improving energy efficiency in manufacturing operations.
Real-Time Energy Intelligence
Measurable Cost Control
Production-Linked Insights
Real-Time Visibility
Faster Response
Higher Productivity
100,000
Offline Storage capacity
600/minute
Capture Signals
Edge Computing
Faster on-site processing
24×7
Live Production Monitoring
Pain points in the industry
Why Utility Monitoring Matters
for Plant Heads
Electricity is one of the largest controllable operational costs in manufacturing,
yet many plants rely only on monthly electricity bills rather than real-time insights.
Key Features
Key Capabilities of the Utility Monitoring IoT
Utility Monitoring IoT system provides real-time energy monitoring dashboards, enabling plant heads to track, control, and optimize electricity usage directly at the machine and line level.
Real-Time Electricity Consumption Monitoring
The system provides continuous monitoring of electrical parameters across the plant, enabling accurate energy analysis.
- kWh energy consumption tracking
- Voltage and current monitoring
- Load profiling for machines and production lines
- Machine-level or feeder-level energy measurement
- Department-wise electricity usage tracking
Continuous data capture ensures complete energy visibility across the manufacturing facility.
RS485 and Modbus Industrial Integration
The hardware supports standard industrial communication protocols, ensuring seamless integration with existing electrical infrastructure.
- Direct integration with smart energy meters
- RS485 communication support
- Modbus protocol compatibility
- Integration with legacy and modern electrical panels
- Reliable industrial data transmission to IoT gateways
Enable quick deployment without disrupting plant operations.
Industrial IoT Gateway for Data Aggregation
An industrial-grade IoT gateway collects, processes, and transmits energy data securely to the MES platform.
- Secure data collection from multiple energy meters
- Edge processing capabilities
- Wi-Fi & Ethernet / LAN connectivity
- Seamless integration with Opus One MES dashboards
The gateway enables plug-and-play industrial IoT deployment with minimal infrastructure changes.
MES Integration with OEE and Production Correlation
Unlike traditional energy monitoring systems, Opus One connects electricity data directly with production performance metrics.
- Energy consumption vs production output
- Energy per part produced
- Energy consumption during machine idle vs runtime
- Breakdown-related energy losses
- OEE vs electricity usage patterns
This helps plant heads measure true energy productivity and manufacturing efficiency rather than just total consumption.
Utility Loss Detection and Real-Time Alerts
The system automatically identifies energy inefficiencies and abnormal consumption patterns, allowing faster corrective actions.
- Sudden electricity consumption spikes
- Idle machine energy draw
- Weekend or non-production energy usage
- Overloaded circuits
- Voltage fluctuations and power instability
Real-time alerts ensure energy losses are detected before they escalate into higher operational costs.
Universal Compatibility
Built for Every Machine,
Ready for Every Industry
Our Wi-Fi OEE Monitoring System seamlessly integrates with virtually anymanufacturing equipment. From legacy machines to modern industrial robots, OpusOne adapts to your factory floor.
- CNC Machines
- VMC / VFC Machines
- Press Machines
- Injection Moulding Machines
- Industrial Robots
- Looms & Textile Equipment
- Assembly Lines
- Packaging Machines
Reliable Hardware, Industrial-Grade Performance
Purpose-built for demanding factory environments with enterprise-grade components and seamless connectivity options.
Display
Industrial Features
- Industrial-grade durability
- IP54 rated enclosure
- Anti-glare display
- Wide operating temperature
- LED status indicators
QR Code
Industrial Features
- IP54 rated enclosure
Wi-Fi
Industrial Features
- Industrial-grade durability
- IP54 rated enclosure
- Anti-glare display
Easy Installation
Plug. Play. Scale.
Real results that impact your bottom line within months, not years
test
Unbox & Mount
Secure the OpusOne device near your machine using the included mounting bracket. No special tools required.
- Wall or panel mount options
- VESA compatible bracket
- Adjustable viewing angle
test
Connect to Wi-Fi
Power on the device and connect to your factory Wi-Fi network through the intuitive setup wizard.
- Simple on-screen setup
- WPA2/WPA3 security
- Automatic reconnection
test
Configure I/O
Connect sensor wires from your machine to the digital I/O terminals for automatic production counting.
- 3 digital inputs available
- 3 digital outputs available
- RS485 for PLC integration
test
Start Monitoring
Access your real-time dashboard from any device. Your factory data is now visible 24/7.
- Web-based portal access
- Mobile responsive design
- Instant data visibility
System Requirements
Power Supply
12-24V DC, 2A min
Wi-Fi Network
2.4GHz or 5GHz
Signal Source
24VDC sensor output
Mounting Space
200 x 150 x 50 mm
Need Help with Installation?
Our technical team provides remote or on-site installation support to ensure your system is up and running smoothly.
Value & ROI
Measurable Gains.
Rapid Payback.
Real results that impact your bottom line within months, not years
5-20%
Productivity Gains
Optimized workflows and better resource utilization
Better
On-Time Delivery
Meet customer commitments consistently
Production
Smarter Production Outcomes
Consistent performance with fewer delays.
Lower
Scrap & Rework
Early defect detection reduces waste
10-30%
Reduced Downtime
Faster response to issues means less production loss
Quick ROI
3–9 Month ROI
Lower downtime. Faster returns.
Installation & Setup – Data Collection Analysis – Decision Making
Implementation of Decision
making & Improvement
observations
ROI Realization
Software & Data Flow
How Your Data Gets From OEE to Opus One Platform
Understand how OpusOne captures, transmits, and processes your production data todeliver actionable insights in real-time.
icon
Machine Signals
Digital I/O captures production events, cycle times, and machine states in real-time.
icon
Wi-Fi Transmission
Data is securely transmitted over your factory Wi-Fi network using encrypted protocols.
icon
Cloud Processing
Our servers process and analyze data, calculating OEE metrics and generating insights.
icon
Dashboard Access
View real-time dashboards and reports from any device, anywhere, anytime.
Sample Reports
Data-Driven Insights at Your Fingertips
Generate comprehensive reports automatically. From daily OEE summaries to detailed
downtime analysis, get the data you need to drive continuous improvement.
icon
Sample Report
Machine: RACB14
Request a demo
Ready to simplify your factory operations?
Manufacturing teams rely on real-time visibility to stay in control.
Trusted by growing teams worldwide
faq
Got questions? We’ve got
answers
Real results that impact your bottom line
within months, not years
What industries can benefit from OpusOne?
OpusOne caters to a wide range of industries including automotive, aerospace, consumer goods, and pharmaceuticals, enhancing their manufacturing processes with digital solutions.
How does OpusOne improve productivity?
By integrating automation and real-time data analytics, OpusOne helps identify bottlenecks, optimize processes, and increase overall operational efficiency.
What is the timeline for implementation?
The implementation timeline varies based on the complexity of your existing systems, but our team ensures a smooth and efficient transition.
Is OpusOne scalable for future growth?
Absolutely! OpusOne is designed to scale with your business needs, adapting to new technologies and processes as you grow.
Is OpusOne scalable for future growth?
Absolutely! OpusOne is designed to scale with your business needs, adapting to new technologies and processes as you grow.
Still have questions?
